What strategies can be optimised to prevent margin leakage in plant operations?

In today’s volatile refining landscape, margin preservation is not just a Financial imperative; it is a strategic necessity. One of the most effective levers to prevent margin leakage is the early detection of performance deviations. By continuously monitoring unit performance and comparing it against high-fidelity models, Axens’ digital platform, Connect'In®, enables refiners to detect subtle degradations, such as catalyst deactivation or feedstock variability, before they escalate into significant losses. In one case, early intervention based on Connect'In® insights helped avoid $4.3 million in losses over 90 days.

Moreover, real-time optimization tools integrated with APC and inferential models allow for dynamic adjustments that maximize yield and minimize energy consumption. Axens’ Horizon services have demonstrated that even top-quartile refineries can unlock additional margin through targeted, low-Capex interventions. A recent study for a 230,000 BPD refinery in Southeast Asia identified 20 actionable solutions, 13 of which were implemented, resulting in a projected $27 million/year margin improvement.

These included optimization of gasoline blending, hydrogen network balancing, and process unit tuning. Revamping ageing assets is another strategic avenue to reduce margin leakage. Rather than building new units, Axens helps clients modernize existing infrastructure to improve energy efficiency, increase throughput, or shift product slates. For example, revamping an aromatics complex led to a 14% reduction in CO₂ emissions and improved Opex through lower energy consumption. Repurposing, meanwhile, offers a transformative path, converting underutilized assets to produce higher-value or lower-carbon products such as hydrotreated vegetable oil (HVO) or sustainable aviation fuel (SAF). This approach not only preserves capital but also accelerates time-to-market. 

Connect'In® is a mark of Axens.